Flow distribution assemblies with shunt tubes and erosion-resistant shunt nozzles

ABSTRACT

A shunt tube assembly includes a shunt tube having an inner flow path for a fluid and defining an opening in a sidewall of the shunt tube. A shunt nozzle is coupled to the sidewall and has an elongate slot defined therethrough and is aligned with the opening to provide fluid communication between the inner flow path and an exterior of the shunt tube. The elongate slot has a length and a height, and the length is greater than the height.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of priority under 35 U.S.C.§371 as a national phase of International Patent Application Serial No.PCT/U52015/055703 entitled “Flow Distribution Assemblies with ShuntTubes and Erosion-Resistant Shunt Nozzles,” and filed on Oct. 15, 2015,which claims the benefit of priority under 35 U.S.C. §119 as anonprovisional of U.S. Provisional Patent Application Ser. No.62/073,240 entitled “Flow Distribution Assemblies with Shunt Tubes andErosion-Resistant Fittings,” and filed on Oct. 31, 2014, the disclosuresof which are hereby incorporated by reference in their entirety for allpurposes.

BACKGROUND

In the course of completing wellbores traversing hydrocarbon-bearingsubterranean formations, it is oftentimes desirable to inject varioustypes of fluids into the wellbore for a number of purposes. For example,steam is often injected into surrounding formations to stimulate theproduction of high-viscosity hydrocarbons, and treatment fluids, such ashydrochloric acid, are often injected into a wellbore to react withacid-soluble materials present within the formation and thereby enlargepore spaces in the formation. In other applications, water or a gas maybe injected into the surrounding formations to maintain formationpressures so that a producing well can continue production. In yet otherapplications, a gravel slurry is deposited in spaced intervalssurrounding well screens during gravel-packing operations.

Such fluid injection operations are typically carried out by placing aninjection string at a desired location within a wellbore. The injectionstring oftentimes includes a wellbore screen assembly that includes oneor more sand screens arranged about perforated production tubing. Theannulus between the sand screens and the wellbore wall is generallygravel-packed to mitigate the influx of formation sands derived from thesurrounding subterranean formations. Packers are customarily set aboveand below sand screen assemblies to seal off the annulus in the zonewhere production fluids flow into the production tubing. The annulusaround the sand screens is then packed with a gravel slurry, whichcomprises relatively coarse sand or gravel suspended within water or agel and acts as a filter to reduce the amount of fine formation sandreaching the screens.

During the gravel packing process, annular sand bridges can form aroundthe sand screen assembly that may prevent the complete circumscribing ofthe screen structure with gravel in the completed well. This incompletescreen structure coverage by the gravel may leave an axial portion ofthe sand screen exposed to the fine formation sand, thereby undesirablylowering the overall filtering efficiency of the sand screen structure.

One approach to avoiding the creation of annulus sand bridges has beento incorporate shunt tubes that longitudinally extend across the sandscreens. The shunt tubes provide flow paths that allow the inflowinggravel slurry to bypass any sand bridges that may be formed andotherwise permit the gravel slurry to enter the annulus between the sandscreens and the wellbore beneath sand bridges, thereby forming thedesired gravel pack beneath it.

BRIEF DESCRIPTION OF THE DRAWINGS

The following figures are included to illustrate certain aspects of thepresent disclosure, and should not be viewed as exclusive embodiments.The subject matter disclosed is capable of considerable modifications,alterations, combinations, and equivalents in form and function, withoutdeparting from the scope of this disclosure.

FIG. 1 depicts a well system that can employ one or more principles ofthe present disclosure.

FIGS. 2A and 2B depict isometric and cross-sectional side views,respectively, of an exemplary shunt tube assembly.

FIGS. 3A and 3B depict isometric and cross-sectional side views,respectively, of another exemplary shunt tube assembly.

FIGS. 4A-4C depict views of yet another exemplary shunt tube assembly.

FIGS. 5A-5B depict views of another exemplary shunt tube assembly.

FIGS. 6A-6B depict views of another exemplary shunt tube assembly.

DETAILED DESCRIPTION

The present disclosure generally relates to downhole fluid flow controland, more particularly, to flow distribution assemblies used todistribute fluid flow into surrounding subterranean formations.

The presently disclosed embodiments enable relatively high rates offluid flow through a flow distribution assembly during gravel packingand/or formation fracture packing operations. The exemplary flowdistribution assemblies described herein include shunt tubes that extendalong the exterior of a work string to allow for fluid communication. Insome embodiments, the shunt tubes include one or more shunt nozzlescoupled to a sidewall of the shunt tube and have an elongate slotdefined therethrough. The elongate slot may be aligned with an openingdefined in the sidewall to provide fluid communication between the innerflow path of the shunt tube and an exterior thereof. The geometry(shape) of the elongate slot may allow for the same or greatercross-sectional flow area as would be provided by a shunt nozzle havinga circular hole, but does not require the circular footprint. As aresult, the shape of the elongate slot may help reduce erosion of theshunt nozzle by increasing the flow area, which has a direct correlationto reduction in velocity for similar flow rates.

Referring to FIG. 1, illustrated is an exemplary well system 100 thatcan employ one or more principles of the present disclosure, accordingto one or more embodiments. As depicted, the well system 100 includes awellbore 102 that extends through various earth strata and may have asubstantially vertical section 104 that may transition into asubstantially horizontal section 106. The upper portion of the verticalsection 104 may have a liner or casing string 108 secured therein with,for example, cement 110. The horizontal section 106 may extend through ahydrocarbon bearing subterranean formation 112. As illustrated, thehorizontal section 106 may be arranged within or otherwise extendthrough an open hole section of the wellbore 102. In other embodiments,however, the horizontal section 106 of the wellbore 102 may also becompleted using casing 108 or the like, without departing from the scopeof the disclosure.

A work string 114 may be positioned within the wellbore 102 and extendfrom the surface (not shown). The work string 114 provides a conduit forfluids to be conveyed either to or from the formation 112. Accordingly,the work string 114 may be characterized as an injection string inembodiments where fluids are introduced or otherwise conveyed to theformation 112, but may alternatively be characterized as productiontubing in embodiments where fluids are extracted from the formation 112to be conveyed to the surface.

At its lower end, the work string 114 may be coupled to or otherwiseform part of a completion assembly 116 generally arranged within thehorizontal section 106. As depicted, the completion assembly 116 mayinclude a plurality of flow distribution assemblies 118 axially offsetfrom each other along portions of the completion assembly 116. Each flowdistribution assembly 118 may include one or more sand screens 120disposed about the outer surface of the work string 114. The sandscreens 120 may comprise fluid-porous, particulate restricting devicesmade from a plurality of layers of a wire mesh that are diffusion bondedor sintered together to form a fluid porous wire mesh screen. In otherembodiments, however, the sand screens 120 may have multiple layers of awoven wire metal mesh material having a uniform pore structure and acontrolled pore size that is determined based upon the properties of theformation 112. For example, suitable woven wire mesh screens mayinclude, but are not limited to, a plain Dutch weave, a twilled Dutchweave, a reverse Dutch weave, combinations thereof, or the like. Inother embodiments, however, the sand screens 120 may include a singlelayer of wire mesh, multiple layers of wire mesh that are not bondedtogether, a single layer of wire wrap, multiple layers of wire wrap orthe like, that may or may not operate with a drainage layer. Thoseskilled in the art will readily recognize that several other sand screen120 designs are equally suitable, without departing from the scope ofthe disclosure.

Each flow distribution assembly 118 may further include one or moreshunt tubes 122 that extend along the exterior of the work string 114and the sand screens 120 and otherwise within an annulus 124 definedbetween the flow distribution assemblies 118 and the wall of thewellbore 102. The shunt tubes 122 may be configured to convey fluids tovarious fluid flow points along the axial length of the completionassembly 116 so that the fluid can be evenly distributed within anannulus 124 defined between the flow distribution assemblies 118 and thewall of the wellbore 102. Accordingly, the completion assembly 116 mayprove useful in various wellbore operations, such as gravel-packingoperations, fracture packing operations, and the like. In such wellboreoperations, the fluids that may be conveyed by the shunt tubes 122 mayinclude, but are not limited to, a fracturing fluid, a proppant slurry,a gravel slurry, and any combination thereof.

The shunt tubes 122 may include at least one transport tube that extendsalong all or substantially all of the completion assembly 116 and mayfurther include one or more packing tubes that extend from the transporttube(s). The transport tube(s) may be open to the annulus 124 at itsuphole end to receive the fluid therein to flow along the entire axiallength of the transport tube(s). The fluid may enter the annulus 124 viaa crossover sub (not shown), or the like, positioned within the workstring 114 above the uppermost flow distribution assembly 118. Thecrossover sub discharges the fluid into the annulus 124 from theinterior of the work string 114, and a portion of the fluid is receivedby the transport tube(s). As the fluid flows down (within) the transporttube(s), a portion of the fluid is able to flow into the packing tubes,which split off the transport tube(s) and run substantially parallelthereto along all or a portion of each flow distribution assembly 118.Each packing tube may include one or more openings or outlets that areable to discharge the fluid into the annulus 124 at predeterminedlocations. In other embodiments, the transport tube(s) may also includeone or more openings or outlets that are able to discharge the fluidinto the annulus 124 at predetermined locations.

The fluids discharged into the annulus 124 may contain solidparticulates, such as gravel, proppant, and other solid debris that,over time, may tend to erode certain surfaces of the shunt tubes 122,such as the openings or outlets facilitate fluid discharge into theannulus 124. As such openings erode and enlarge, usually those near theupper end of the shunt tubes 122, more and more of the fluid (e.g., agravel slurry) will exit through the enlarged openings with less andless of the fluid will reach the lower, smaller openings in the shunttubes 122. This increased flow through the larger, eroded openings cancause “sand bridges” (i.e., the accumulation of particulates) to form inthe shunt tubes 122, which may block any further substantial downwardflow in the affected shunt tubes 122. Once this occurs, no further fluidcan be delivered through the affected shunt tube 122 to the downholeportions of the wellbore 102. Another effect of having enlarged oreroded openings due to erosion is a loss of control in the direction ofthe flow. If the flow is redirected towards the sand screens 120, damagecould ensue and thereby cause a loss in filtering capability.

According to the present disclosure, the fluid flow points provided inthe shunt tubes 122 may each include a shunt fitting and/or a shuntnozzle. The shunt fittings and the shunt nozzles associated with theshunt tubes 122 may be made of erosion-resistant materials and therebyprovide an erosion-resistant exit pathway for fluids to exit the shunttubes 122 into the annulus 124.

It should be noted that even though FIG. 1 depicts the flow distributionassemblies 118 as being arranged in an open hole portion of the wellbore102, alternative embodiments are contemplated herein where one or moreof the flow distribution assemblies 118 is arranged within a casedportion of the wellbore 102. Further, even though FIG. 1 depicts theflow distribution assemblies 118 as being arranged in the horizontalsection 106 of the wellbore 102, those skilled in the art will readilyrecognize that the principles of the present disclosure are equally wellsuited for use in vertical wells, deviated wellbores, slanted wells,multilateral wells, combinations thereof, and the like. As used herein,directional terms such as above, below, upper, lower, upward, downward,left, right, uphole, downhole and the like are used in relation to theillustrative embodiments as they are depicted in the figures, the upwarddirection being toward the top of the corresponding figure and thedownward direction being toward the bottom of the corresponding figure,the uphole direction being toward the surface of the well and thedownhole direction being toward the toe of the well.

Referring now to FIGS. 2A and 2B, with continued reference to FIG. 1,illustrated are isometric and cross-sectional side views, respectively,of an exemplary shunt tube assembly 200, according to one or moreembodiments. The shunt tube assembly 200 (hereafter the “assembly 200”)may be used in the exemplary well system 100 of FIG. 1. Moreparticularly, the assembly 200 may be positioned or otherwise arrangedat various points within one or more of the shunt tubes 122 of the flowdistribution assemblies 118 of FIG. 1. As illustrated, the assembly 200may include a shunt tube 202 and an associated shunt fitting 204. Theshunt tube 202 may be the same as or similar to any of the shunt tubes122 of FIG. 1. Accordingly, the shunt tube 202 may be a transport tubeor a packing tube, as described above, and may be configured to conveyfluids from the annulus 124 (FIG. 1) to various fluid flow points alongthe axial length of the completion assembly 116 (FIG. 1).

At least one of the fluid flow points may correspond to the location ofthe shunt fitting 204. As illustrated, the shunt fitting 204 may bepositioned inline in the shunt tube 202. More particularly, the shuntfitting 204 may interpose a first or upper portion 206 a of the shunttube 202 and a second or lower portion 206 b of the shunt tube 202. Theshunt fitting 204 may be attached to the upper and lower portions 206a,b of the shunt tube 202 at corresponding attachment locations 207 aand 207 b, respectively, via a variety of attachment means including,but not limited to, welding, brazing, adhesives, mechanical fastening(e.g., screws, bolts, pins, snap rings, etc.), shrink fitting,interference fitting, or any combination thereof. While only one shuntfitting 204 is shown as positioned inline in the shunt tube 202, it willbe appreciated that multiple shunt fittings 204 may be connected inlinein the shunt tube 202 to provide a corresponding multiple number offluid flow point locations.

The shunt tube 202 may be generally tubular or, in other words, in thegeneral shape of a tube or a conduit. As best seen in FIG. 2B, the shunttube 202 may provide a fluid conduit or inner flow path 208 for the flowof a fluid, as shown by the arrows A. The fluid A may be any of thefluids mentioned above including, but not limited to, a fracturingfluid, a gravel slurry, and any combination thereof. In the illustratedembodiment, the shunt tube 202 and the shunt fitting 204 are depicted ashaving a generally rectangular cross-sectional shape. In otherembodiments, however, the shunt tube 202 and the shunt fitting 204 mayalternatively exhibit a circular cross-section or any other polygonalcross-section, such as triangular, square, trapezoidal, or any otherpolygonal shape. In yet other embodiments, the shunt tube 202 and theshunt fitting 204 may exhibit a cross-sectional shape that issubstantially oval or kidney shaped, without departing from the scope ofthe disclosure.

As illustrated, the shunt fitting 204 may include an outlet 210 thatfluidly communicates with the inner flow path 208. The outlet 210 mayprovide an opening or exit port for at least a portion of the fluid A tobe discharged from the assembly 200. In some embodiments, the outlet 210may comprise a hole that is flush with the body of the shunt fitting204. In other embodiments, as illustrated, the outlet 210 may comprise anozzle feature that extends from the body of the shunt fitting 204 at anangle 212 (FIG. 2B) with respect to the longitudinal axis of the shunttube 202. The angle 212 may be any angle ranging between 1° and 179°with respect to the shunt tube 202. In the illustrated embodiment, theangle 212 is about 25° offset from the shunt tube 202 (i.e., itslongitudinal axis), but could alternatively be greater or smaller than25°, without departing from the scope of the disclosure.

In order to prevent or otherwise reduce erosion resulting from thecirculating fluid A during operation, the shunt fitting 204 may be madeof an erosion-resistant material. The erosion-resistant material may be,but is not limited to, a carbide (e.g., tungsten, titanium, tantalum, orvanadium), a carbide embedded in a matrix of cobalt or nickel bysintering, a cobalt alloy, a ceramic, a surface hardened metal (e.g.,nitrided metals, heat-treated metals, carburized metals, hardened steel,etc.), a steel alloy (e.g. a nickel-chromium alloy, a molybdenum alloy,etc.), a cermet-based material, a metal matrix composite, ananocrystalline metallic alloy, an amorphous alloy, a hard metallicalloy, or any combination thereof.

In other embodiments, or in addition thereto, the interior or innerwalls of the shunt fitting 204 may be clad or coated with anerosion-resistant material, such as tungsten carbide, a cobalt alloy, orceramic. In such embodiments, the outlet 210 of the shunt fitting 204 inparticular may be clad or coated with the erosion-resistant material.The interior or inner walls of the shunt fitting 204 may be clad withthe erosion-resistant material via any suitable process including, butnot limited to, weld overlay, thermal spraying, laser beam cladding,electron beam cladding, vapor deposition (chemical, physical, etc.), anycombination thereof, and the like.

In some embodiments, the shunt tube 202 may also be configured to beerosion-resistant or otherwise comprise an erosion-resistant material.For instance, the shunt tube 202 may be made of a carbide or a ceramic.In other embodiments, the shunt tube 202 may be made of a metal or othermaterial that is internally cladded with an erosion-resistant materialsuch as, but not limited to, tungsten carbide, a cobalt alloy, orceramic. In yet other embodiments, the shunt tube 202 may be made of amaterial that has been surface hardened, such as surface hardened metals(e.g., via nitriding), heat treated metals (e.g., using 13 chrome),carburized metals, or the like. In even further embodiments, the shunttube 202, or a portion thereof, may be an Aramid-type fiber tube, suchas a Kevlar or other type of composite material.

Referring now to FIGS. 3A and 3B, illustrated are isometric andcross-sectional side views, respectively, of another exemplary shunttube assembly 300, according to one or more embodiments. The shunt tubeassembly 300 (hereafter the “assembly 300”) may be used in the exemplarywell system 100 of FIG. 1 and may be similar in some respects to theassembly 200 of FIGS. 2A-2B and therefore may be best understood withreference thereto, where like numerals indicate like components notdescribed again in detail. Similar to the assembly 200, the assembly 300may include the shunt tube 202, including the upper and lower portions206 a,b thereof. The assembly 300 may also include the shunt fitting204, including the outlet 210 that fluidly communicates with the innerflow path 208 to provide an exit for at least a portion of the fluid Ato be discharged from the shunt tube 202. In some embodiments, asillustrated, the outlet 210 may be a nozzle that extends from the bodyof the shunt fitting 204 at the angle 212 (FIG. 3B).

Unlike the assembly 200 of FIGS. 2A-2B, however, the assembly 300 mayfurther include a first or upper coupling assembly 302 a and a second orlower coupling assembly 302 b. The upper coupling assembly 302 a mayinclude an upper coupling 304 a and the lower coupling assembly 302 bmay include a lower coupling 304 b. The upper and lower couplings 304a,b may be configured to be coupled or otherwise attached to opposingends of the shunt fitting 204. More particularly, a first or upper end306 a of the shunt fitting 204 may be coupled to the upper coupling 304a, and a second or lower end 306 b of the shunt fitting 204 may becoupled to the lower coupling 304 b. The upper and lower couplings 304a,b may be coupled to the upper and lower ends 306 a,b of the shuntfitting 204, respectively, via a variety of attachment means including,but not limited to, welding, brazing, adhesives, mechanical fastening(e.g., screws, bolts, pins, snap rings, etc.), shrink fitting,interference fitting, or any combination thereof.

In some embodiments, the upper and lower couplings 304 a,b may bedirectly coupled or otherwise attached to the upper and lower portions206 a,b of the shunt tube 202, respectively, such as via welding,brazing, adhesives, mechanical fastening (e.g., screws, bolts, pins,snap rings, etc.), shrink fitting, interference fitting, or anycombination thereof. In other embodiments, however, one or both of theupper and lower coupling assemblies 302 a,b may include an extension,such as an upper extension 308 a and/or a lower extension 308 b. Theupper and lower extensions 308 a,b may be similar in cross-sectionalshape to the shunt tube 202. At one end, the upper and lower extensions308 a,b may be coupled or otherwise attached to the upper and lowercouplings 304 a,b, respectively, and at the other end, the upper andlower extensions 308 a,b may be coupled or otherwise attached to theupper and lower portions 206 a,b of the shunt tube 202, respectively.Such coupling engagements of the upper and lower extensions 308 a,b withthe upper and lower couplings 304 a,b and the upper and lower portions206 a,b of the shunt tube 202 may be accomplished via any one ofwelding, brazing, adhesives, mechanical fastening (e.g., screws, bolts,pins, snap rings, etc.), shrink fitting, interference fitting, or anycombination thereof.

Those skilled in the art will readily appreciate the advantage that theassembly 300 may provide to a well operator. For instance, the upper andlower coupling assemblies 302 a,b may allow the shunt fitting 204 to becoupled to the upper and lower couplings 304 a,b, and optionally theupper and lower extensions 308 a,b, offsite prior to being delivered toa well site. This may allow a manufacturer to properly braze the upperand lower couplings 304 a,b to the shunt fitting 204, which may be madeof a material that is difficult to weld, such as tungsten carbide. Onceon site, the upper and lower coupling assemblies 302 a,b may be coupledto the upper and lower portions 206 a,b of the shunt tube 202,respectively, using common attachment means, such as welding or brazingtechniques, an adhesive, a mechanical fastener, shrink fitting,interference fitting, and any combination thereof.

Referring now to FIGS. 4A-4C, illustrated are various views of yetanother exemplary shunt tube assembly 400, according to one or moreembodiments. More particularly, FIG. 4A depicts an isometric view of theshunt tube assembly 400 (hereafter the “assembly 400”), FIG. 4B depictsa cross-sectional side view of one embodiment of the assembly 400, andFIG. 4C depicts a cross-sectional side view of a second embodiment ofthe assembly 400. The assembly 400 may be used in the exemplary wellsystem 100 of FIG. 1 and may be similar in some respects to theassemblies 200 and 300 of FIGS. 2A-2B and 3A-3B and therefore may bebest understood with reference thereto, where like numerals indicatelike components not described again.

Similar to the assemblies 200 and 300 of FIGS. 2A-2B and 3A-3B, theassembly 400 may include the shunt tube 202 for conveying the fluid Atherethrough. Unlike the assemblies 200 and 300, however, the assembly400 may further include a shunt nozzle 402 that extends from the shunttube 202 at an angle 404 (FIGS. 4B and 4C) that provides an exit for atleast a portion of the fluid A to be discharged from the assembly 400.The angle 404 may be any angle ranging between 1° and 179° with respectto the shunt tube 202. In the illustrated embodiment, the angle 404 isabout 45° offset from the shunt tube 202, but could alternatively begreater or smaller than 45°, without departing from the scope of thedisclosure.

The shunt nozzle 402 may be a substantially tubular structure thatfluidly communicates with an opening 406 defined in the shunt tube 202.The opening 406 may provide fluid communication between the inner flowpath 208 of the shunt tube 202 and an exterior thereof. In someembodiments, as illustrated, the shunt nozzle 402 may have a generallycircular or cylindrical cross-sectional shape. In other embodiments,however, the shunt nozzle 402 may alternatively have a polygonalcross-sectional shape, such as triangular, square, rectangular,trapezoidal, or any other polygonal shape. In yet other embodiments, theshunt nozzle 402 may exhibit a cross-sectional shape that issubstantially oval or kidney shaped, without departing from the scope ofthe disclosure.

Similar to the shunt fitting 204 of FIGS. 2A-2B and 3A-3B, the shuntnozzle 402 may also be made of an erosion-resistant material, such asthose discussed above. In other embodiments, or in addition thereto, theinterior or inner surfaces of the shunt nozzle 402 may be clad or coatedwith an erosion-resistant material, such as tungsten carbide, a cobaltalloy, or ceramic. In some embodiments, the erosion-resistant materialmay be applied to the inner surfaces of the shunt nozzle 402 before theshunt nozzle 402 is coupled to the shunt tube 202. In other embodiments,the erosion-resistant material may be applied to the inner surfaces ofthe shunt nozzle 402 after the shunt nozzle 402 is coupled to the shunttube 202, without departing from the scope of the disclosure.

In the embodiment shown in FIG. 4B, the shunt nozzle 402 is depicted asbeing inserted into the opening 406 and otherwise coupled to the shunttube 202 as recessed into the opening 406. In such embodiments, theshunt nozzle 402 may be coupled to the shunt tube 202 within the opening406 via a variety of attachment means including, but not limited to,welding, brazing, adhesives, mechanical fastening (e.g., screws, bolts,pins, snap rings, etc.), shrink fitting, interference fitting, or anycombination thereof.

In the embodiment shown in FIG. 4C, the shunt nozzle 402 is depicted asbeing aligned with the opening 406 and flush mounted to the outersurface of the shunt tube 202. In such embodiments, the shunt nozzle 402may be coupled or otherwise attached to the outer surface of the shunttube 202 via one or more of welding, brazing, adhesives, mechanicalfastening (e.g., screws, bolts, pins, snap rings, etc.), or anycombination thereof.

FIGS. 5A and 5B illustrate isometric and cross-sectional isometricviews, respectively, of another exemplary shunt tube assembly 500,according to one or more additional embodiments. The shunt tube assembly500 (hereafter the “assembly 500”) may be used in the exemplary wellsystem 100 of FIG. 1 and may be similar in some respects to theassemblies 200, 300, and 400 described above, and therefore may be bestunderstood with reference thereto, where like numerals indicate likecomponents not described again.

Similar to the assemblies 200, 300, 400, for example, the assembly 500may include a shunt tube 202 for conveying the fluid A therethrough. Theassembly 500 may further include a shunt nozzle 502 that extends from asidewall of the shunt tube 202. The shunt nozzle 502 may generallycomprise a six-sided block having a first end 504 a, a second end 504 bopposite the first end 504 a, a top 506 a, a bottom 506 b opposite thetop 506 a, a first side 508 a, and a second side 508 b opposite thefirst side 508 a. In the illustrated embodiment, the shunt nozzle 502 isformed in the general shape of a rectangular block, but couldalternatively comprise a square block, without departing from the scopeof the disclosure.

An elongate slot 510 is defined through the shunt nozzle 502 and extendsbetween the opposing first and second sides 508 a,b. As shown in FIG.5A, the elongate slot 510 has a length 512 and a height 514. The length512 comprises a horizontal measurement of the elongate slot 510generally parallel to the shunt tube 202 and extending in the directiongenerally between the first and second ends 504 a,b. The height 514comprises a vertical measurement of the elongate slot 510 generallyorthogonal to the shunt tube 202 and extending in the directiongenerally between the top and bottom 506 a,b. As seen in FIG. 5B, theelongate slot 510 also exhibits a depth 516, which comprises ameasurement extending between the first and second sides 508 a,b.

As used herein, the term “elongate slot” refers to an opening defined inthe shunt nozzle 502 where magnitudes or measurements of the length 512and the height 514 of the opening are dissimilar. In the illustratedembodiment, for instance, the length 512 of the opening is greater thanthe height 514. In other embodiments, however, the height 514 of theopening may alternatively be greater than the length 512, withoutdeparting from the scope of the disclosure. The elongate slot 510 mayexhibit any cross-sectional shape where the length 512 of the opening isgreater than the height 514. In the illustrated embodiment, for example,the cross-sectional shape of the elongate slot 510 is generallyrectangular with rounded ends or corners, but could alternativelyinclude sharp or squared off ends. In other embodiments, however, thecross-sectional shape of the elongate slot 510 may be oval, ovoid,kidney shaped, a parallelogram, or any other polygonal cross-sectionalshape where the length 512 is greater than the height 514.

The geometry (shape) of the elongate slot 510 may prove advantageous increating a smoother transition for the fluid A to exit therectangular-shaped shunt tube 202, which may help reduce erosion. Moreparticularly, the flow of the fluid A through the elongate slot 510 maybe more laminar as compared to circular nozzles, and thereby exhibitingmore favorable flow characteristics. Moreover, the geometry of theelongate slot 510 may allow for the same or greater cross-sectional flowarea as would be provided by a shunt nozzle having a circular hole, butdoes not require the circular footprint, which may not physically fit onthe sidewall of the rectangular shunt tube 202. Accordingly, the shapeof the elongate slot 510 may help reduce the erosion of the shunt nozzle502 by increasing the flow area, which has a direct correlation to thereduction in velocity for similar flow rates.

In some embodiments, the length 512 of the elongate slot 510 may beconstant along the depth 516 between the opposing first and second sides508 a,b. In other embodiments, however, the magnitude of the length 512may vary along the depth 516, without departing from the scope of thedisclosure. In such embodiments, for example, the length 512 may taperoutward from the first side 508 a to the second side 508 b along thedepth 516, or alternatively taper inward from the first side 508 a tothe second side 508 b. In other embodiments, the length 512 may vary(i.e., undulate) along the depth 516 between the opposing first andsecond sides 508 a,b, without departing from the scope of the presentdisclosure.

Moreover, in some embodiments, the height 514 of the elongate slot 510may be constant across the length 512 of the elongate slot 510, but mayalternatively vary across the length 512. In the illustrated embodiment,for example, the elongate slot 510 may define a channel 518 that extendsalong the depth 516 between the opposing first and second sides 508 a,band exhibits a height 520 that is greater than the height 514. Stateddifferently, the channel 518 may comprise a portion of the elongate slot510 where the height 514 increases as compared to remaining portions ofthe elongate slot 510. In some embodiments, as illustrated, the channel518 may comprise a generally round conduit that extends along the depth516. In other embodiments, however, the channel 518 may exhibit othercross-sectional shapes, such as oval, ovoid, polygonal, or anycombination thereof, where the height 514 along the length 512 isincreased.

Similar to the assembly 400 of FIG. 4C, the shunt nozzle 502 may bealigned with the opening 406 and flush mounted to the outer surface ofthe shunt tube 202. More particularly, the elongate slot 510 may bealigned with the opening 406, and the first side 508 a of the shuntnozzle 502 may be coupled or otherwise secured to the outer surface ofthe shunt tube 202 via one or more of welding, brazing, adhesives,mechanical fastening (e.g., screws, bolts, pins, snap rings, etc.), orany combination thereof. The elongate slot 510 provides fluidcommunication between the inner flow path 208 of the shunt tube 202 andthe exterior and thereby provides an exit for at least a portion of thefluid A to be discharged from the assembly 500.

The elongate slot 510 may extend at an angle 522 (FIG. 5B) with respectto the shunt tube 202. The angle 522 may be any angle ranging between 1°and 179° with respect to the shunt tube 202. In the illustratedembodiment, the angle 522 is about 75° offset from the shunt tube 202,but could alternatively be greater or smaller than 75°, withoutdeparting from the scope of the disclosure.

In some embodiments, the shunt nozzle 502 may be made of a block oferosion-resistant material, such as any of the erosion-resistantmaterials listed herein. In other embodiments, however, and since thegeometry of the elongate slot 510 helps reduce erosion of the shuntnozzle 502 by increasing the flow area (i.e., larger cross-sectionalarea=lower fluid velocity=less erosion), the shunt nozzle 502 mayalternatively be made of more common steels or less resilient metalalloys. Use of stainless steels, such as chromium or nickel alloyshaving an SAE designation 3XX or harder or even less resilient alloys,reduces the complexity in manufacturing as many erosion-resistantmaterials require more elaborate and costly securing practices such asbrazing. Accordingly, the shunt nozzle 502 may alternatively be madewith a variety of heat-treated stainless steels such as, but not limitedto, 410SST, 135MY, or 30MY (SAE designations). As will be appreciated,using such basic metallic materials may prove advantageous in allowingsimpler manufacturing construction, where basic welding practices andother securing means can be used.

In yet other embodiments, or in addition to the foregoing materials, theinterior or inner surfaces of the shunt nozzle 502 may be clad or coatedwith an erosion-resistant material, such as tungsten carbide, a cobaltalloy, or ceramic. In some embodiments, the erosion-resistant materialmay be applied to the inner surfaces of the shunt nozzle 502 before itis coupled to the shunt tube 202. In other embodiments, theerosion-resistant material may be applied to the inner surfaces of theshunt nozzle 502 after it is coupled to the shunt tube 202, withoutdeparting from the scope of the disclosure.

FIGS. 6A and 6B illustrate isometric and cross-sectional isometricviews, respectively, of another exemplary shunt tube assembly 600,according to one or more additional embodiments. The shunt tube assembly600 (hereafter the “assembly 600”) may be used in the exemplary wellsystem 100 of FIG. 1 and may be similar in some respects to the assembly500 of FIGS. 5A-5B and therefore may be best understood with referencethereto, where like numerals indicate like components not describedagain.

Similar to the assembly 500, for example, the assembly 600 may include ashunt tube 202 for conveying the fluid A therethrough. The assembly 600may further include the shunt nozzle 502, as generally described above.An elongate slot 602 is defined through the shunt nozzle 502 and extendsbetween the opposing first and second sides 508 a,b. As with theelongate slot 510 of FIGS. 5A-5B, the elongate slot 602 has the length512, the height 514, and the depth 516, where the length 512 and theheight 514 of the elongate slot 602 are dissimilar. In the illustratedembodiment, the length 512 is depicted as greater than the height 514,but could alternatively be smaller than the height 514, withoutdeparting from the scope of the disclosure. The elongate slot 602 mayexhibit any cross-sectional shape where the length 512 of the opening isgreater than the height 514. In the illustrated embodiment, for example,the cross-sectional shape of the elongate slot 602 is generallyrectangular with rounded corners, but could alternatively exhibit across-sectional shape that is oval, ovoid, kidney shaped, aparallelogram, or any other polygonal cross-sectional shape where thelength 512 is greater than the height 514.

Again, the shunt nozzle 502 and, more particularly, the elongate slot602 may be aligned with the opening 406 and flush mounted to the outersurface of the shunt tube 202 via one or more of welding, brazing,adhesives, mechanical fastening (e.g., screws, bolts, pins, snap rings,etc.), or any combination thereof. The elongate slot 602 provides fluidcommunication between the inner flow path 208 of the shunt tube 202 andthe exterior and thereby provides an exit for at least a portion of thefluid A to be discharged from the assembly 600. Moreover, the elongateslot 602 may extend at the angle 522 (FIG. 6B) with respect to the shunttube 202 and to inner flow path 208.

While the assemblies 200, 300, 400, 500, and 600 described herein aregenerally described with reference to injection operations, where afluid A is injected into a surrounding formation 112 (FIG. 1) via theshunt tubes 202 and associated shunt fittings 204 or shunt nozzles 402,those skilled in the art will readily appreciate that the assemblies200, 300, 400, 500, and 600 may alternatively be used in productionoperations (e.g., reverse-flow operations), without departing from thescope of the disclosure. For example, in other embodiments, the flow ofanother fluid (not shown), such as a formation fluid, may instead bedrawn into the shunt tubes 202 via the shunt fittings 204 or shuntnozzles 402, 502, or 602 and subsequently into the inner flow path 208to be produced to the surface. Advantageously, the erosion-resistantcharacteristics of the shunt tubes 202 and the shunt fittings 204 andshunt nozzles 402, 502, or 602 allow the fluids to be produced withoutcausing detrimental eroding.

Embodiments disclosed herein include:

A. A shunt tube assembly that includes a shunt tube having an inner flowpath for a fluid and defining an opening in a sidewall of the shunttube, and a shunt nozzle coupled to the sidewall and having an elongateslot defined therethrough and aligned with the opening to provide fluidcommunication between the inner flow path and an exterior of the shunttube, wherein the elongate slot has a length and a height, and thelength is dissimilar to the height.

B. A method that includes introducing a flow distribution assembly intoa wellbore on a work string, the flow distribution assembly including atleast one shunt tube extending along an exterior of the work string andhaving an inner flow path for a fluid and defining an opening in asidewall of the shunt tube, conveying the fluid into the inner flow pathfrom an annulus defined between the work string and the wellbore, anddischarging at least a portion of the fluid from the at least one shunttube at a shunt nozzle coupled to the sidewall and having an elongateslot defined therethrough and aligned with the opening to provide fluidcommunication between the inner flow path and the annulus, wherein theelongate slot has a length and a height, and the length is dissimilar tothe height.

Each of embodiments A and B may have one or more of the followingadditional elements in any combination: Element 1: wherein the shunttube is rectangular and the length is a horizontal measurement of theelongate slot generally parallel to the shunt tube, and the height is avertical measurement of the elongate slot generally orthogonal to theshunt tube. Element 2: wherein the length is greater than the height.Element 3: wherein the shunt nozzle is a six-sided block comprising afirst end and a second end opposite the first end, a top and a bottomopposite the top, and a first side and a second side opposite the firstside, wherein the elongate slot extends between the first and secondsides. Element 4: wherein the length of the elongate slot is constantbetween the first and second sides. Element 5: wherein the length of theelongate slot varies between the first and second sides. Element 6:wherein the height of the elongate slot is constant across the length ofthe elongate slot. Element 7: wherein the height of the elongate slotvaries across the length of the elongate slot. Element 8: wherein theelongate slot defines a channel where the height is increased ascompared to remaining portions of the elongate slot. Element 9: whereinthe channel exhibits a cross-sectional shape selected from the groupconsisting of circular, oval, ovoid, polygonal, and any combinationthereof. Element 10: wherein the shunt nozzle is coupled to the sidewallby at least one of welding, brazing, an adhesive, a mechanical fastener,and any combination thereof. Element 11: wherein the elongate slotextends from the shunt tube at an angle ranging between 1° and 179° withrespect to the shunt tube. Element 12: wherein the shunt nozzlecomprises a material selected from the group consisting of a carbide, acarbide embedded in a matrix of cobalt or nickel by sintering, a cobaltalloy, a ceramic, a surface-hardened metal, a steel alloy, a chromiumalloy, a nickel alloy, a cermet-based material, a metal matrixcomposite, a nanocrystalline metallic alloy, an amorphous alloy, a hardmetallic alloy, or any combination thereof. Element 13: wherein an innersurface of the shunt nozzle is clad with an erosion-resistant materialselected from the group consisting of a carbide, a cobalt alloy, and aceramic.

Element 14: further comprising preventing erosion of the shunt fitting,wherein the shunt nozzle comprises an erosion-resistant materialselected from the group consisting of a carbide, a ceramic, a cobaltalloy, a surface-hardened metal, stainless steel, a nickel-chromiumalloy, a molybdenum alloy, and a chromium steel. Element 15: furthercomprising preventing erosion of an inner surface of the shunt nozzle,wherein the inner surface of the shunt nozzle is clad with anerosion-resistant material selected from the group consisting of acarbide, a cobalt alloy, and a ceramic. Element 16: further comprisingpreventing erosion of the at least one shunt tube, wherein the at leastone shunt tube comprises an erosion-resistant material selected from thegroup consisting of a carbide, a ceramic, a cobalt alloy, asurface-hardened metal, and a composite. Element 17: wherein theelongate slot defines a channel where the height is increased along thelength as compared to remaining portions of the elongate slot. Element18: wherein the shunt tube is rectangular and the length is a horizontalmeasurement of the elongate slot generally parallel to the shunt tubeand the height is a vertical measurement of the elongate slot generallyorthogonal to the shunt tube, and wherein the length is greater than theheight.

By way of non-limiting example, exemplary combinations applicable to Aand B include: Element 3 with Element 4; Element 3 with Element 5;Element 7 with Element 8; and Element 8 with Element 9.

Therefore, the disclosed systems and methods are well adapted to attainthe ends and advantages mentioned as well as those that are inherenttherein. The particular embodiments disclosed above are illustrativeonly, as the teachings of the present disclosure may be modified andpracticed in different but equivalent manners apparent to those skilledin the art having the benefit of the teachings herein. Furthermore, nolimitations are intended to the details of construction or design hereinshown, other than as described in the claims below. It is thereforeevident that the particular illustrative embodiments disclosed above maybe altered, combined, or modified and all such variations are consideredwithin the scope of the present disclosure. The systems and methodsillustratively disclosed herein may suitably be practiced in the absenceof any element that is not specifically disclosed herein and/or anyoptional element disclosed herein. While compositions and methods aredescribed in terms of “comprising,” “containing,” or “including” variouscomponents or steps, the compositions and methods can also “consistessentially of” or “consist of” the various components and steps. Allnumbers and ranges disclosed above may vary by some amount. Whenever anumerical range with a lower limit and an upper limit is disclosed, anynumber and any included range falling within the range is specificallydisclosed. In particular, every range of values (of the form, “fromabout a to about b,” or, equivalently, “from approximately a to b,” or,equivalently, “from approximately a-b”) disclosed herein is to beunderstood to set forth every number and range encompassed within thebroader range of values. Also, the terms in the claims have their plain,ordinary meaning unless otherwise explicitly and clearly defined by thepatentee. Moreover, the indefinite articles “a” or “an,” as used in theclaims, are defined herein to mean one or more than one of the elementthat it introduces. If there is any conflict in the usages of a word orterm in this specification and one or more patent or other documentsthat may be incorporated herein by reference, the definitions that areconsistent with this specification should be adopted.

As used herein, the phrase “at least one of” preceding a series ofitems, with the terms “and” or “or” to separate any of the items,modifies the list as a whole, rather than each member of the list (i.e.,each item). The phrase “at least one of” allows a meaning that includesat least one of any one of the items, and/or at least one of anycombination of the items, and/or at least one of each of the items. Byway of example, the phrases “at least one of A, B, and C” or “at leastone of A, B, or C” each refer to only A, only B, or only C; anycombination of A, B, and C; and/or at least one of each of A, B, and C.

What is claimed is:
 1. A shunt tube assembly, comprising: a shunt tubehaving an inner flow path for a fluid and defining an opening in asidewall of the shunt tube; and a shunt nozzle coupled to the sidewalland having an elongate slot defined the ethrough and aligned with theopening to provide fluid communication between the inner flow path andan exterior of the shunt tube, wherein the elongate slot has a lengthand a height, and the length is dissimilar to the height.
 2. The shunttube assembly of claim 1, wherein the shunt tube is rectangular and thelength is a horizontal measurement of the elongate slot generallyparallel to the shunt tube, and the height is a vertical measurement ofthe elongate slot generally orthogonal to the shunt tube.
 3. The shunttube assembly of claim 2, wherein the length is greater than the height.4. The shunt tube assembly of claim 1, wherein the shunt nozzle is asix-sided block comprising: a first end and a second end opposite thefirst end; a top and a bottom opposite the top; and a first side and asecond side opposite the first side, wherein the elongate slot extendsbetween the first and second sides.
 5. The shunt tube assembly of claim4, wherein the length of the elongate slot is constant between the firstand second sides.
 6. The shunt tube assembly of claim 4, wherein thelength of the elongate slot varies between the first and second sides.7. The shunt tube assembly of claim 1, wherein the height of theelongate slot is constant across the length of the elongate slot.
 8. Theshunt tube assembly of claim 1, wherein the height of the elongate slotvaries across the length of the elongate slot.
 9. The shunt tubeassembly of claim 8, wherein the elongate slot defines a channel wherethe height is increased as compared to remaining portions of theelongate slot.
 10. The shunt tube assembly of claim 9, wherein thechannel exhibits a cross-sectional shape selected from the groupconsisting of circular, oval, ovoid, polygonal, and any combinationthereof.
 11. The shunt tube assembly of claim 1, wherein the shuntnozzle is coupled to the sidewall by at least one of welding, brazing,an adhesive, a mechanical fastener, and any combination thereof.
 12. Theshunt tube assembly of claim 1, wherein the elongate slot extends fromthe shunt tube at an angle ranging between 1° and 179° with respect tothe shunt tube.
 13. The shunt tube assembly of claim 1, wherein theshunt nozzle comprises a material selected from the group consisting ofa carbide, a carbide embedded in a matrix of cobalt or nickel bysintering, a cobalt alloy, a ceramic, a surface-hardened metal, a steelalloy, a chromium alloy, a nickel alloy, a cermet-based material, ametal matrix composite, a nanocrystalline metallic alloy, an amorphousalloy, a hard metallic alloy, or any combination thereof.
 14. The shunttube assembly of claim 1, wherein an inner surface of the shunt nozzleis clad with an erosion-resistant material selected from the groupconsisting of a carbide, a cobalt alloy, and a ceramic.
 15. A method,comprising: introducing a flow distribution assembly into a wellbore ona work string, the flow distribution assembly including at least oneshunt tube extending along an exterior of the work string and having aninner flow path for a fluid and defining an opening in a sidewall of theshunt tube; conveying the fluid into the inner flow path from an annulusdefined between the work string and the wellbore; and discharging atleast a portion of the fluid from the at least one shunt tube at a shuntnozzle coupled to the sidewall and having an elongate slot definedtherethrough and aligned with the opening to provide fluid communicationbetween the inner flow path and the annulus, wherein the elongate slothas a length and a height, and the length is dissimilar to the height.16. The method of claim 15, further comprising preventing erosion of theshunt fitting, wherein the shunt nozzle comprises an erosion-resistantmaterial selected from the group consisting of a carbide, a ceramic, acobalt alloy, a surface-hardened metal, stainless steel, anickel-chromium alloy, a molybdenum alloy, and a chromium steel.
 17. Themethod of claim 15, further comprising preventing erosion of an innersurface of the shunt nozzle, wherein the inner surface of the shuntnozzle is clad with an erosion-resistant material selected from thegroup consisting of a carbide, a cobalt alloy, and a ceramic.
 18. Themethod of claim 15, further comprising preventing erosion of the atleast one shunt tube, wherein the at least one shunt tube comprises anerosion-resistant material selected from the group consisting of acarbide, a ceramic, a cobalt alloy, a surface-hardened metal, and acomposite.
 19. The method of claim 15, wherein the elongate slot definesa channel where the height is increased along the length as compared toremaining portions of the elongate slot.
 20. The method of claim 15,wherein the shunt tube is rectangular and the length is a horizontalmeasurement of the elongate slot generally parallel to the shunt tubeand the height is a vertical measurement of the elongate slot generallyorthogonal to the shunt tube, and wherein the length is greater than theheight.